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215026

128

Revision A

1028502

Figure 4.107: Driveline

Remove four M12 hex flange head bolts (A) securing
driveline assembly (B) to hub drive (C).

1028504

Figure 4.108: Drum and Tube Shield

–

Cutaway View

Slide driveline (A) downwards, tilt it to the side, and pull
the driveline up and out of the drum.

1028507

Figure 4.109: Driven Drum

–

View from Above

10. Use an 18 mm deep socket and an extension to remove

four M12 bolts (A) and washers holding drum disc
assembly (B) in place.

11. Remove drum disc assembly (B).

MAINTENANCE AND SERVICING

Summary of Contents for R216

Page 1: ...R216 Rotary Disc Header Operator s Manual 215026 Revision A Original Instruction The harvesting specialists...

Page 2: ...n this publication MacDon Industries Ltd reserves the right to make changes at any time without notice Noise Levels The A weighted sound pressure level inside the operator s station of a typical self...

Page 3: ...ne settings in all relevant MacDon publications Failure to do so may compromise machine function and machine life and may result in a hazardous situation MacDon provides warranty for Customers who ope...

Page 4: ...1240 Windrower page 24 Revised topic Service Dept 3 3 3 Connecting R216 SP Hydraulics and Electrical to an M1240 Windrower page 29 Replaced the following topics Connecting Disc Header Hydraulics Using...

Page 5: ...e 90 Added links to removing the outboard cutterbar discs Engineering Installing Cutterbar Discs page 92 Added links to installing the outboard cutterbar discs Engineering Installing Cutterbar Discs p...

Page 6: ...B6847 page 171 Added topic Tech Pubs 5 2 Double Windrow Attachment MD C2070 page 172 Added topic Tech Pubs 5 3 Disc Feed Plate Kit MD B6669 page 173 Added topic Tech Pubs 5 5 Adjustable Gauge Roller...

Page 7: ...the header in the spaces provided below 1027799 A Figure 1 Serial Number Location Header model R216 Rotary Disc Header Serial number Model year The serial number plate A is located on the left side o...

Page 8: ......

Page 9: ...2 1 Engaging and Disengaging Header Safety Props M1240 Windrower 20 3 3 Attaching Rotary Disc Header to M1240 Windrower 22 3 3 1 Installing Forming Shield 22 3 3 2 Attaching Header to M1240 Windrower...

Page 10: ...soil Moisture 67 3 10 3 Weather and Topography 67 3 10 4 Windrow Characteristics 68 3 10 5 Driving on Windrow 68 3 10 6 Using Chemical Drying Agents 68 3 11 Transporting the Header 69 Chapter 4 Mainte...

Page 11: ...126 Installing Left Driven Drum and Driveline 129 Removing Right Driven Drum and Driveline 132 Installing Right Driven Drum and Driveline 135 4 6 8 Cutterbar Spindle Shear Pin 138 Removing Cutterbar...

Page 12: ...5 6 Polyurethane Intermeshing Roller MD B6661 176 5 7 Steel Intermeshing Roller MD B6662 177 5 8 Adjustable Skid Shoes Kit MD B6848 178 5 9 Tall Crop Divider Kit MD B6808 179 Chapter 6 Troubleshootin...

Page 13: ...indicates important safety messages in this manual and on safety signs on the machine This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Carefully read and follow the safety message acc...

Page 14: ...ded will result in death or serious injury WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury It may also be used to alert against unsafe p...

Page 15: ...e glasses or goggles Heavy gloves Wet weather gear Respirator or filter mask 1000005 Figure 1 3 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitabl...

Page 16: ...machine function and or safety It may also shorten the machine s life To avoid injury or death from unexpected startup of the machine ALWAYS stop the engine and remove the key from the ignition before...

Page 17: ...achine Make sure all components are tight and that steel lines hoses and couplings are in good condition before applying pressure to hydraulic systems Keep hands feet clothing and hair away from all m...

Page 18: ...high pressure Makeshift repairs will fail suddenly and create hazardous and unsafe conditions 1001207 Figure 1 12 Hydraulic Pressure Hazard Wear proper hand and eye protection when searching for high...

Page 19: ...have with regard to future malfunctions or shorter lifespan It is very important that welding on the header is not attempted while the header is connected to the windrower If an Operator needs to do...

Page 20: ...repair part displays the current safety sign Replacement safety signs are available from Dealer Parts Department 1 7 1 Installing Safety Decals 1 Clean and dry the installation area 2 Decide exactly...

Page 21: ...215026 9 Revision A 1 8 Locating Safety Decals Figure 1 15 Safety Sign Decal Locations Top View 1030633 A B A MD 307746 B MD 325706 Figure 1 16 Safety Sign Decals 1030634 A B SAFETY...

Page 22: ...215026 10 Revision A Figure 1 17 Safety Sign Decal Locations Rear View 1028515 A B C C A MD 190546 B MD 325070 C Reflector SAFETY...

Page 23: ...rials exiting at high speed Stop machine look listen and wait for all movement to stop before approaching Failure to comply could result in death or serious injury Disengage power take off shut off tr...

Page 24: ...annually Ensure that all safety signs are installed and legible Make certain everyone is clear of machine before starting engine and during operation Keep riders off the machine Keep all shields in p...

Page 25: ...0 rpm Blade max tip speed 83 6 m s 187 mph Effective cutting width 4942 mm 16 ft 2 in Minimum Cutting height 20 mm 25 32 in at 8 header tilt Cutting angle range 0 8 below horizontal Adjustable shoes o...

Page 26: ...pm Polyurethane rolls Optional Roll type Polyurethane intermeshing conditioner rolls Roll length 3275 mm 129 in Roll diameter 254 mm 10 in roll diameter outer on 203 mm 8 in OD tube Roll speed 1009 rp...

Page 27: ...Curtain B Disc Drum Right C 10 Disc Cutterbar D Conditioner Rolls E Drive Shield Left F Hydraulic Motor G Center Link Tube Welded to Frame H Hazard Brake Lights J Suspended Drum Right Figure 2 2 R216...

Page 28: ...ocket in head internal wrenching hexagon drive also known as an Allen key and various other synonyms hp Horsepower HPT display Harvest Performance Tracker display module on an M1 Series Windrower JIC...

Page 29: ...product of a force X lever arm length usually measured in Newton meters Nm or foot pounds lbf ft Torque angle A tightening procedure where fitting is assembled to a precondition finger tight and then...

Page 30: ......

Page 31: ...from the operator s seat for binding or interfering parts NOTE Until you become familiar with the sound and feel of your new header be extra alert and attentive CAUTION Before investigating an unusua...

Page 32: ...the HEADER UP A switch to raise header to maximum height NOTE If one end of the header does NOT fully raise rephase the lift cylinders as follows a Press and hold the HEADER UP switch A until both cy...

Page 33: ...the safety prop will not disengage raise the header to release the prop a Turn lever A away from the header to raise the safety prop until the lever locks into the vertical position b Repeat for the o...

Page 34: ...r s seat for any reason 1 Stop engine and remove key from ignition 1030560 A B C D Figure 3 4 Forming Shield and Windrower 2 Position forming shield A in between windrower legs as shown 3 Remove lynch...

Page 35: ...r of Windrower Leg 6 Remove lynch pin A and washer B from straight pin C 1030490 A B C D Figure 3 7 Rubber Strap Securing Forming Shield onto Windrower Leg 7 Attach rubber strap D to straight pin C at...

Page 36: ...IMPORTANT If the center link is too low it may contact the header as the windrower approaches the header for hookup 1030516 A B C Figure 3 9 Header Support 2 Remove hairpin A from clevis pin B and re...

Page 37: ...display to remove float remove float manually For instructions refer to windrower operator s manual for instructions 1015851 A B Figure 3 12 HPT Display 6 Press rotary scroll knob A on display to high...

Page 38: ...to drive slowly forward until feet engage the supports and header nudges forward 12 Ensure feet A are properly engaged in supports B 1016903 A B C Figure 3 16 Hydraulic Center Link 13 Self Aligning H...

Page 39: ...to be sure all bystanders have cleared the area e Start the engine 1014786 A Figure 3 18 GSL 15 Press HEADER UP switch A to raise the header to maximum height NOTE If one end of the header does NOT f...

Page 40: ...the safety props on both lift cylinders as follows NOTE If the safety prop will not disengage raise the header to release the prop a Turn lever A away from the header to raise the safety prop until th...

Page 41: ...hydraulic couplers 1 Open the windrower s left platform For instructions refer to windrower operator s manual 2 Using a clean rag remove dirt and moisture from the couplers on the left side of the win...

Page 42: ...per ready configuration A Steps 6 page 30 to 9 page 31 Rotary disc only hard plumbed configuration B Step 10 page 32 to 11 page 32 Rotary disc ready configuration B with quick couplers installed Steps...

Page 43: ...cal Draper Ready 8 Connect the hydraulic hoses to the windrower with quick coupler fittings as follows a Connect disc pressure hose A with coupler B and torque to 205 226 Nm 151 167 lbf ft b Connect d...

Page 44: ...226 Nm 151 167 lbf ft b Connect disc return hose D to hard plumb fitting E and torque to 205 226 Nm 151 167 lbf ft c Connect case drain hose F to fitting G 11 To connect electrical harness refer to S...

Page 45: ...ittings and elbows A from the rotary disc header hydraulic pressure and return connections 1027609 A B Figure 3 32 Quick Couplers on Rotary Disc Ready Windrower 14 Install the male quick coupler at wi...

Page 46: ...nd torque to 205 226 Nm 151 167 lbf ft c Connect case drain hose E to fitting F with relief valve pointing towards the ground NOTE If required loosen fitting F and retighten as needed to ensure relief...

Page 47: ...ness A to adapter harness B 20 Connect electric baffle control harness C to adapter harness D if installed 1030621 A Figure 3 36 Electrical Connection at Windrower 21 Check electrical connection A at...

Page 48: ...ION Check to be sure all bystanders have cleared the area 1030975 A Figure 3 37 GSL 1 Start the engine and press switch A to lower the header to the ground 2 Shut down the engine and remove the key fr...

Page 49: ...rame 1030631 A Figure 3 40 Hose Bundle Storage Position 7 Rest hydraulic hose bundle A on header for storage as shown 1030630 A B C D Figure 3 41 Electrical Connection 8 Disconnect main header harness...

Page 50: ...djustable strap B 1000812 A B C Figure 3 43 Header Supports 11 Remove hairpin B from clevis pin A Remove clevis pin from header support C on both sides of header Windrowers with center link self align...

Page 51: ...78 B A Figure 3 45 GSL 15 Use HEADER TILT cylinder switches A on GSL to release load on center link cylinder 16 Operate the link lift cylinder with REEL UP switch B to disengage the center link from t...

Page 52: ...always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Stop engine and remove key from ignition 1030490 A B C D Figure 3 48 Rubber Strap Secur...

Page 53: ...pin A and clevis pin B securing forming shield C to bolts and spacers D Repeat at the opposite side 1030499 A B B Figure 3 50 Forming Shield and Windrower 8 Dismount forming shield A from bolts and s...

Page 54: ...3 5 1 Opening Driveshields CAUTION To reduce the risk of personal injury do NOT operate the machine without the driveshields in place and secured 1028426 Figure 3 51 Left Driveshield NOTE Images shown...

Page 55: ...Driveshield Outboard Side 2 Lift the outboard driveshield panel toward the outboard end of the header 1028446 A B Figure 3 54 Driveshield Inboard Side 3 Grab handle A and lift the other half of endshi...

Page 56: ...in this procedure are for the left driveshield the right driveshield is similar 1028453 A Figure 3 55 Driveshield Lock Latch 1 Lift lock latch A to disengage driveshield lock 1028455 A Figure 3 56 Lef...

Page 57: ...ached at the front and the sides of the header ALWAYS keep curtain lowered when operating the disc header IMPORTANT Replace curtain A if it becomes worn or damaged For instructions refer to 4 9 1 Insp...

Page 58: ...igure 3 61 Cutterbar Curtain and Retaining Clips NOTE Cutterbar curtain A is held in place between the tines of retaining clips B 3 6 2 Closing Cutterbar Curtain CAUTION To avoid injury keep hands and...

Page 59: ...id shoe or gauge roller settings Adjust the cutting height for optimum cutting performance and to prevent build up inside the disc header Excessive build up of mud and soil can lead to poor crop flow...

Page 60: ...death from unexpected start up or fall of a raised machine stop engine remove key and engage windrower lift cylinder safety props before going under machine for any reason 1 Raise the header fully shu...

Page 61: ...llers are available to provide different cutting heights NOTE The left gauge roller is shown in the illustrations in this procedure The right gauge roller is opposite The gauge roller has three positi...

Page 62: ...osition To adjust the gauge rollers to the intermediate position follow these steps 1028064 A B Figure 3 68 Gauge Roller Secured in Lowest Working Position 1 Support the gauge roller and remove two ly...

Page 63: ...r Secured with Plate 3 Swing gauge roller A fully backward and reinstall scraper plate B in slot IMPORTANT The scraper plate should be installed from the outboard side with its tab facing down as show...

Page 64: ...he cab through the Harvest Performance Tracker HPT The header float feature allows the header to closely follow ground contours and respond quickly to sudden changes or obstacles The float setting is...

Page 65: ...cutting conditions such as native grasses set the disc speed to MAXIMUM In light crops reduce the disc header s disc speed while maintaining ground speed NOTE Operating the disc header at the minimum...

Page 66: ...ory setting visually inspect the roll gap to ensure that there is no metal to metal contact between the upper and lower rolls Adjusting Roll Gap Steel Rolls To adjust the roll gap follow the procedure...

Page 67: ...n 1028125 A B Figure 3 76 Roll Gap Adjustment Left Side Shown 3 Loosen jam nut A on both sides of the conditioner 4 Turn lower nut B counterclockwise until the upper roll rests on the lower roll 5 Tur...

Page 68: ...y reason 1 Lower the header to the ground 2 Shut down the engine and remove the key from the ignition 1028475 A B Figure 3 77 Roll Tension Adjuster 3 Loosen jam nut A on both sides of the conditioner...

Page 69: ...and remove the key from the ignition before leaving the operator s seat for any reason Roll timing is factory set and should not require adjustment however if there is excessive noise coming from the...

Page 70: ...A securing yoke plate B NOTE Only three of the four bolts are shown in the illustration 1030266 A B C D E Figure 3 82 Conditioner Drive 5 Secure bottom roll A 6 Manually rotate upper roll B counterclo...

Page 71: ...ng Make a second mark B on the yoke flange and align it with the mark on the gearbox flange 1030424 A B Figure 3 84 Conditioner Drive 9 Determine center point A between the two marks on the yoke plate...

Page 72: ...e clean and free of lubricant NOTE Only three of the four bolts are shown in the illustration 12 Apply medium strength threadlocker Loctite 242 or equivalent and tighten bolt A Torque to 95 Nm 70 lbf...

Page 73: ...er allows only a few days to cut and bale A narrower windrow may be preferable for ease of pick up and when drying is not critical for example when cutting for silage or green feed Positioning Forming...

Page 74: ...ge 63 To position the rear baffle follow these steps WARNING To avoid injury or death from unexpected start up of machine always stop the engine and remove the key from the ignition before leaving the...

Page 75: ...1029233 A Figure 3 88 Deflector Fins Under Rear Baffle View from Below 1 Deflector fins A are located on the underside of the rear baffle NOTE There are two fins on the left and two fins on the right...

Page 76: ...evision A 1028789 A Figure 3 90 Left Deflector Fins in Storage Position NOTE Deflector fins A can be put in storage position by removing existing nut and bolt and reattaching fins on top of the baffle...

Page 77: ...ury or death from unexpected start up or fall of a raised machine always stop engine and remove key before leaving the operator s seat and always engage safety props before going under the machine for...

Page 78: ...NOTE Some parts removed from illustration for clarity 6 Apply medium strength threadlocker Loctite 243 or equivalent to M8 hex flange head bolt B and then loosely install at the outboard end of deflec...

Page 79: ...Use a moisture tester or estimate level If ground is wet due to irrigation wait until soil moisture drops below 45 If ground is wet due to frequent rains cut hay when weather allows and let the forage...

Page 80: ...ales to minimize handling and stacking problems Properly conditioned Prevents excessive leaf damage 3 10 5 Driving on Windrow Driving on previously cut windrows that will not be raked can lengthen dry...

Page 81: ...215026 69 Revision A 3 11 Transporting the Header For information on transporting the header when attached to the windrower refer to your windrower operator s manual OPERATION...

Page 82: ......

Page 83: ...y from machinery Walk around to make sure no one is under on or close to it Wear close fitting clothing and protective shoes with slip resistant soles As well carry with you any protective clothing an...

Page 84: ...ssing broken or not working correctly NOTE Use proper procedure when searching for pressurized fluid leaks Refer to 4 13 1 Checking Hydraulic Hoses and Lines page 170 2 Clean all lights and reflective...

Page 85: ...eason CAUTION To avoid personal injury perform the following procedures before servicing disc header or opening drive covers 1 Lower the header fully If you need to perform service in the raised posit...

Page 86: ...Figure 4 5 Safety Equipment Wear protective shoes with slip resistant soles a hard hat protective glasses or goggles and heavy gloves 1003660 Figure 4 6 Safety Around Equipment Be aware that if more t...

Page 87: ...gerous when working with electrical equipment Be sure all electrical outlets and tools are properly grounded Use adequate light for the job at hand Reinstall all shields removed or opened for service...

Page 88: ...ep copies of your maintenance records Refer to 4 4 1 Maintenance Schedule Record page 76 CAUTION Carefully follow all safety messages Refer to 4 3 Recommended Safety Procedures page 74 4 4 1 Maintenan...

Page 89: ...4 7 1 Checking and Changing Conditioner Roll Timing Gearbox Oil page 149 Check header drive gearbox lubricant Refer to 4 8 1 Checking Oil in Header Drive Gearbox page 152 Every 250 Hours2 Change roll...

Page 90: ...lt tension and adjust tension if necessary Inspecting Conditioner Drive Belt page 160 4 4 3 Preseason Servicing CAUTION Review the operator s manual to refresh your memory on safety and operating reco...

Page 91: ...sary 4 Check for broken components and order replacements from your Dealer Immediate repair of these items will save time and effort at beginning of next season 5 Replace or tighten any missing or loo...

Page 92: ...bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and...

Page 93: ...Pivot B Bearing Roller Conditioner Two Places C U Joint Conditioner Driveline Two Places D Slip Joint Conditioner Driveline3 E Idler Tensioner Pivot F Bearing Feed Roll G Tensioner Arm MAINTENANCE AND...

Page 94: ...ler Conditioner Two Places B U Joint Upper Driveline Two Places C Slip Joints Conditioner Drivelines4 D U Joint Lower Driveline Two Places E Idler Pivot MAINTENANCE AND SERVICING 4 Use high temperatur...

Page 95: ...xpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason WARNING Exercise caution when working around the blades Bla...

Page 96: ...et B from cutterbar Oil level must be up to the inspection plug hole If additional lubricant is required continue following this procedure and refer to the next step If additional lubricant is NOT req...

Page 97: ...d the area 15 Start the engine and raise the header fully 16 Shut down the engine and remove the key from the ignition Engage the windrower lift cylinder safety props 17 Remove the block from under th...

Page 98: ...ward 2 Place block under each end of the disc header as shown so the right end is lower than the left end IMPORTANT Always drain lubricant from the right end of the disc header Draining lubricant from...

Page 99: ...Draining the Cutterbar page 86 1 Start the engine and raise the header fully 1028587 A B B Figure 4 19 Cutterbar Access Plug 2 Place a block under each end of the disc header so the right end is highe...

Page 100: ...erbar Discs 1030965 A Cutterbar discs A are interchangeable and can be moved to a spindle that rotates in the opposite direction as long as the disc is in usable condition and the blades are oriented...

Page 101: ...cracks excessive wear and disc distortion Replace any damaged or worn discs as required NOTE Any damaged or worn cutterbar discs are NOT repairable and must be replaced if damaged 2 Inspect the cutter...

Page 102: ...om the ignition before leaving the operator s seat for any reason CAUTION Disc blades have two sharp cutting edges that can cause serious injury Exercise caution and wear gloves when working with blad...

Page 103: ...ation while loosening bolts 6 Remove four M12 bolts A and washers 1029255 A B Figure 4 26 Cutterbar Disc and Cap 7 Remove cutterbar disc cap A 8 Remove cutterbar disc B 9 To remove the outboard cutter...

Page 104: ...hat it is positioned at a 90 angle in relation to the adjacent discs 3 Install cutterbar disc cap B and secure assembly with four M12 bolts and washers C Torque bolts to 85 Nm 63 lbf ft WARNING Ensure...

Page 105: ...ear pins Refer to 4 6 8 Cutterbar Spindle Shear Pin page 138 to replace shear pin 1019153 A B C Figure 4 30 Cutterbar Spindles IMPORTANT Spindles that rotate clockwise have right leading threading and...

Page 106: ...flat level surface 2 Raise the header 3 Shut off the engine and remove the key from the ignition 4 Engage the windrower lift cylinder safety props For instructions refer to 3 2 1 Engaging and Disengag...

Page 107: ...ire disc when swapping spindles 1011389 A Figure 4 34 Spacer Plate 10 Remove spacer plate A NOTE The area around the spindle must be cleaned thoroughly to prevent debris from entering into the cutterb...

Page 108: ...Figure 4 37 Underside of Cutterbar Spindles 1028991 A B NOTE Right discs A and left discs B are slightly offset as shown depending on which idler gear the spindle is turning Spindles that rotate clock...

Page 109: ...turn and reinstall Recheck the timing before bolting the hub down and tightening all of the nuts Figure 4 38 Checking Timing with Disc Timing Tool View from Above 1028991 A A B B C D A Disc Timing Too...

Page 110: ...disc header is on a flat level surface and is tilted all the way back 3 Determine the suitable spindle rotation pattern for the crop conditions For instructions refer to 4 6 3 Cutterbar Spindles page...

Page 111: ...ck and adjust disc timing as follows NOTE There are an odd number of teeth on the cutterbar gears which can make spindle hub alignment difficult a Place one end of disc timing tool A on adjacent disc...

Page 112: ...bolts IMPORTANT Blades are rotation specific Switch the entire disc when swapping spindles 13 Position disc A on the spindle ensuring that it is positioned at a 90 angle in relation to the adjacent d...

Page 113: ...opposite ends that are free to rotate horizontally on a specially designed shoulder bolt Blade A has two cutting edges and can be flipped over so that the blade does not need replacing as often The bl...

Page 114: ...blades immediately A B C 1003888 Figure 4 49 Disc Blades A Blade Wear to Center Line B Elongated Hole C Maximum Elongation 21 mm 13 16 in 1 Check daily that the disc blades are securely attached to th...

Page 115: ...es or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage Inspect the blade attachment hardware each time the blades are changed Refer to...

Page 116: ...d installed five times Head A is worn flush with the bearing surface of the blade Diameter of the bolt neck is worn B 3 mm 1 8 in NOTE This can occur when disc speed is set too low in cane type crops...

Page 117: ...ower lift cylinder safety props before going under machine for any reason CAUTION Disc blades have two sharp cutting edges that can cause serious injury Exercise caution and wear gloves when working w...

Page 118: ...igure 4 56 Disc Blade 6 Place a pin or equivalent in the front hole of the neighboring rock guard to prevent disc rotation while loosening blade bolts 7 Clean debris from the blade attachment area 8 R...

Page 119: ...ivalent in the front hole of the rock guard to prevent disc rotation while tightening blade bolts 2 Install a new or reversed blade A with shoulder bolt B onto disc C IMPORTANT Nuts are one time use o...

Page 120: ...ite Inspecting Accelerators CAUTION Disc blades have two sharp cutting edges that can cause serious injury Exercise caution and wear gloves when working with blades WARNING To avoid bodily injury or d...

Page 121: ...before leaving the operator s seat for any reason CAUTION Disc blades have two sharp cutting edges that can cause serious injury Exercise caution and wear gloves when working with blades IMPORTANT Al...

Page 122: ...ng bolts 6 Line up the hole in the rock guard with the bolt to be removed 7 Remove nut A flange bolt B and disc blade C from the disc Discard the nut 1029025 A B C D Figure 4 64 Accelerator Removal 8...

Page 123: ...elerator Installation 1 Place a pin or equivalent in the front hole of the neighboring rock guard to prevent disc rotation while tightening blade bolts IMPORTANT Accelerators are unidirectional both c...

Page 124: ...ped with rock guards at each cutting disc location Rock guards prevent the cutterbar from digging into the ground and protect the disc from coming in contact with stones and other debris Periodically...

Page 125: ...of their original thickness 5 Check for loose or missing fasteners tighten or replace fasteners as needed Removing Rock Guards 1003622 A Figure 4 70 Rock Guards 1 Remove two hex head screws washers an...

Page 126: ...if there are gaps on either side and install two hex head screws washers and lock nuts A NOTE Lock nuts A and washers are installed on top 3 Torque hardware to 68 Nm 50 lbf ft 4 6 7 Drums 1028190 A B...

Page 127: ...eader fully 2 Shut off the engine and remove the key from the ignition 1028174 A Figure 4 75 Cutterbar Curtain 3 Open cutterbar curtain A For instructions refer to 3 6 1 Opening Cutterbar Curtain page...

Page 128: ...drums for abrasion A The wear limit for abrasion is reached when the material thickness of the drums is less than 3 mm 1 8 in Replace as required WARNING Ensure the cutterbar is completely clear of fo...

Page 129: ...blades NOTE Illustrations show right suspended drum left suspended drum is opposite 1 Raise the header 2 Shut down the engine and remove the key from the ignition 3 Engage the windrower lift cylinder...

Page 130: ...d bolts A securing suspended drum B to shaft C and remove suspended drum B 1028536 A B Figure 4 83 Driveline Shield 7 Remove two M10 hex flange head bolts A and remove driveline shield B 8 Repeat Step...

Page 131: ...right suspended drum the left suspended drum is opposite 1028537 A C B Figure 4 84 Suspended Drum 1 Position suspended drum B to shaft C as shown 2 Apply a bead of medium strength threadlocker Loctit...

Page 132: ...ore going under machine for any reason WARNING Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades 1 Raise the header 2 Shut...

Page 133: ...ove driveline shield B 1030509 A Figure 4 89 Left Driveshield 6 Open left driveshield A For instructions refer to 3 5 1 Opening Driveshields page 42 1030515 A B C D A Figure 4 90 Gear Hub and Shield P...

Page 134: ...by rotating tensioner A clockwise 11 Remove belt B from the pulley and slide the belt through opening C 12 Remove the ratchet to release the tensioner Installing left suspended drive belt 1030550 A B...

Page 135: ...made transparent to show connection between spindle spline A and gear hub B 1030541 B B A C Figure 4 95 Gear Hub and Shield Plate 18 Slide shield plate A forward and tighten two bolts B 19 Install an...

Page 136: ...Drum Drive Belt DANGER To avoid bodily injury or death from unexpected start up or fall of a raised machine stop engine remove key and engage windrower lift cylinder safety props before going under ma...

Page 137: ...ight Drum Belts 5 Using a ratchet release belt tension by rotating counterclockwise on tensioner A 6 Remove belt B from the pulleys Installing right suspended drive belt 1030553 A B Figure 4 101 Right...

Page 138: ...engine remove key and engage windrower lift cylinder safety props before going under machine for any reason WARNING Exercise caution when working around the blades Blades are sharp and can cause seri...

Page 139: ...loosen two M10 hex flange head bolts B Remove driveline shield C 1028510 A B Figure 4 105 Driveline Shield 6 Remove two M10 hex flange head bolts A and remove driveline shield B 1030941 A B Figure 4 1...

Page 140: ...108 Drum and Tube Shield Cutaway View 9 Slide driveline A downwards tilt it to the side and pull the driveline up and out of the drum 1028507 A B Figure 4 109 Driven Drum View from Above 10 Use an 18...

Page 141: ...es are sharp and can cause serious injury Wear gloves when handling blades 1030991 A B Figure 4 110 Driven Spindle 1 Ensure spacer A is on the spindle 2 Apply an anti seize compound to spindle splines...

Page 142: ...high strength threadlocker Loctite 262 or equivalent around the threads of four M12 hex flange head bolts A Use the bolts to secure driveline assembly B to hub drive C Torque bolts to 100 Nm 74 lbf f...

Page 143: ...of medium strength threadlocker Loctite 243 or equivalent around the threads of two M10 hex flange head bolts A and two M10 hex flange head bolts B Use bolts A and B to secure driveline shield C in pl...

Page 144: ...ury Wear gloves when handling blades 1 Raise the header 2 Shut down the engine and remove the key from the ignition 3 Engage the windrower safety props For instructions refer to 3 2 1 Engaging and Dis...

Page 145: ...d bolts A and two drum shields B 1028516 A B Figure 4 121 Driveline Shield 7 Remove two M10 hex flange head bolts A and remove driveline shield B 1028518 A A B C Figure 4 122 Driveline 8 Remove four M...

Page 146: ...ds tilt it to the side and pull the driveline up and out of the drum 1028520 A B Figure 4 124 Right Driven Drum View from Above 10 Use an 18 mm deep socket and an extension to remove four M12 bolts A...

Page 147: ...he blades Blades are sharp and can cause serious injury Wear gloves when handling blades 1030991 A B Figure 4 125 Right Driven Spindle 1 Ensure spacer A is on the spindle 2 Apply an anti seize compoun...

Page 148: ...h threadlocker Loctite 262 or equivalent around the threads of four M10 hex flange head bolts A Use the bolts to secure driveline assembly B to hub drive C Torque the bolts to 57 5 Nm 42 lbf ft 102851...

Page 149: ...of medium strength threadlocker Loctite 243 or equivalent around the threads of two M10 hex flange head bolts A and two M10 hex flange head bolts B Use bolts A and B to secure driveline shield C in pl...

Page 150: ...orientation of the shear pins during replacement Spindles that rotate clockwise have right leading threading Spindles that rotate counterclockwise have left leading threading NOTE Once a spindle has...

Page 151: ...props For instructions refer to 3 2 1 Engaging and Disengaging Header Safety Props M1240 Windrower page 20 1030429 A Figure 4 135 Cutterbar Curtain 4 Open cutterbar curtain A For instructions refer t...

Page 152: ...ure 4 137 Cutterbar Spindle 7 Remove spacer plate A and retaining ring B 1029010 A Figure 4 138 Safecut Spindle Nut Wrench 8 Remove the M12 bolt and remove safecut spindle nut wrench A from its storag...

Page 153: ...onal direction of that spindle MUST remain the same that is a clockwise spindle must maintain its clockwise rotation Failure to maintain a proper rotation pattern can result in damage to the spindle a...

Page 154: ...evision A 1030744 A B A Figure 4 142 Removing Shear Pin 13 Remove damaged shear pins A using pin punch B 1030721 A Figure 4 143 Belleville Washer 14 Remove and clean Belleville washer A MAINTENANCE AN...

Page 155: ...Spindle 1 Fill the space above the bearing with grease Refer to the inside back cover of this manual for a list of recommended fluids lubricants and capacities for the machine 2 Reinstall Belleville...

Page 156: ...the step in the hub 1030741 A B Figure 4 147 Cutterbar Spindle 6 Install nut A and spacer plate B 1016425 A B C D Figure 4 148 Spindle Nut 7 Attach safecut spindle nut wrench B 90 D to the torque wren...

Page 157: ...installation procedure Install cutterbar disc A For instructions refer to to Installing Cutterbar Discs page 92 Install left driven drum B For instructions refer to Installing Left Driven Drum and Dri...

Page 158: ...esponding spindles to suit crop conditions Each spindle and disc pair is designed to rotate in one direction and must be changed as sets when altering crop flows 1028073 Figure 4 153 R216 Cutterbar Re...

Page 159: ...ge to the spindle and or cutterbar components Safecut components shear pin will not work if spindles are used in the wrong orientation Changing R216 SP Cutterbar Crop Stream Configuration Figure 4 155...

Page 160: ...Tool MD 307954 B Safecut Spindle Nut Wrench MD 246314 NOTE A disc timing tool A MD 307954 is provided with the header and is located on the panel on the right side of the header For instructions on us...

Page 161: ...e back cover for a list of recommended fluids lubricants and capacities WARNING To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from th...

Page 162: ...arbox oil level 1028655 A B Figure 4 160 Roll Timing Gearbox 6 Clean around oil level sight glass A and breather B on the inboard side of the gearbox 7 Ensure that the lubricant is level with the top...

Page 163: ...Engaging and Disengaging Header Safety Props M1240 Windrower page 20 11 Clean around oil drain plug A on the bottom of the gearbox and around oil level plug B on the inboard side of the gearbox 12 Pl...

Page 164: ...Perform subsequent oil changes every 250 hours or annually preferably before the start of the cutting season IMPORTANT Check the gearbox oil level when the oil is warm If the oil is cold idle the mach...

Page 165: ...k plug A removed or slightly runs out of the check hole 10 If necessary remove fill plug B and add lubricant to the gearbox through the fill hole until lubricant runs out of the check hole with check...

Page 166: ...plug B on the inboard side of the gearbox 2 Place a 4 liter 1 gal US container under drain A 3 Remove oil drain plug A 4 Allow sufficient time for oil to drain reinstall oil drain plug A and tighten 5...

Page 167: ...Always keep the curtain down when operating the header WARNING To reduce the risk of personal injury and machine damage do NOT operate the machine without curtain installed and in good condition Fore...

Page 168: ...panel NOTE Cutterbar removed from illustration for clarity 3 Loosen six lock nuts C securing curtain B to the front of the header frame Do NOT remove nuts at this time NOTE Curtain seam is on the insi...

Page 169: ...outboard end 1028485 A B C Figure 4 171 Cutterbar Curtain View from Below 4 Tighten six lock nuts C securing curtain B to the front of the header frame NOTE Cutterbar removed from illustration for cla...

Page 170: ...l of a raised machine stop engine remove key and engage windrower lift cylinder safety props before going under machine for any reason WARNING Exercise caution when working around the blades Blades ar...

Page 171: ...earings are located on the inboard side of the feed roll tensioner assembly driver pulley and left roll arm 7 Inspect conditioner driveline U joints B for signs of wear or damage If the U joints need...

Page 172: ...Belt Check the belt tension after the first 25 hours and then check and inspect for damage or wear every 100 hours WARNING To avoid bodily injury or death from unexpected startup of the machine always...

Page 173: ...34 A B C Figure 4 180 Belt Tension Spring 6 Measure the length of belt tensioner spring A and ensure spring length B is 17 mm 11 16 in in accordance with spring tension decal C If the spring length re...

Page 174: ...page 42 1029371 A B C D E Figure 4 181 Conditioner Drive 4 Turn jam nut A counterclockwise to unlock the tension adjustment 5 Turn jam nut A and adjuster nut B counterclockwise to fully extend tension...

Page 175: ...2 Shut down the engine and remove the key from the ignition 1028480 A Figure 4 182 Left Driveshield 3 Open left driveshield A For instructions refer to 3 5 1 Opening Driveshields page 42 1028349 A B...

Page 176: ...e the rod pivot point with the bracket 8 Measure the length of tensioner spring C For proper belt tension dimension D should be set to 17 mm 11 16 in 9 To adjust spring tension loosen jam nut A by tur...

Page 177: ...the right driveshield is similar 1028426 Figure 4 187 Left Driveshield 1 Open the driveshields For instructions refer to 3 5 1 Opening Driveshields page 42 1028552 A B C Figure 4 188 Retaining Pins on...

Page 178: ...move 4 11 2 Installing Driveshields CAUTION Do NOT operate the machine without the driveshields in place and secured NOTE Images shown in this procedure are for the left driveshield the right driveshi...

Page 179: ...bolt C and a hex flange center lock nut 3 Secure the front and rear of the inboard half of the driveshield with retaining pin B bolt C and a hex flange center lock nut NOTE The inboard half of the dr...

Page 180: ...from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and remove the key from the ignition 1027801 A B C D E Figure 4 193 Left Amber Hazard Signal Light 2 Detach h...

Page 181: ...sen nut C from the end of the sensor and remove the sensor from bracket D 7 Remove the nut from the end of the new sensor install the new sensor into bracket D and secure with nut C 8 Connect sensor w...

Page 182: ...nozzles which eject fluids under high pressure If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may res...

Page 183: ...stems from feeding under the rolls Cutterbar deflectors may not be well suited for some crop and field conditions Refer to the following table Table 5 1 Conditions for Using Cutterbar Deflectors Crop...

Page 184: ...y a double windrow when installed on a windrower The kit includes a draper deck linkage assembly hydraulics and installation instructions MD C2070 consists of MD B6693 Deck MD B6694 Mounting frame and...

Page 185: ...late Kit MD B6669 The tall crop feed plates assist the feeding of tall crops into the conditioner by encouraging material flow from behind the cage deflectors Do not use this kit in medium to light al...

Page 186: ...c Remote Baffle Kit MD B6664 1028576 Figure 5 3 Electric Remote Baffle Kit The Electric Remote Baffle kit MD B6664 allows the operator to electronically adjust the disc header baffle from inside the w...

Page 187: ...028366 Figure 5 4 Adjustable Gauge Roller The adjustable gauge roller kit allows the header to achieve the desired cutting height for optimum cutting performance Adjustable gauge rollers are recommend...

Page 188: ...ing and crushing the stem in several places which allows the release of moisture resulting in faster drying times A polyurethane roll conditioner is better suited for crushing stems while providing re...

Page 189: ...several places which allows the release of moisture resulting in faster drying times Steel rolls with a larger gap up to 25 mm 1 in may be desirable for thick stemmed cane type crops however too large...

Page 190: ...365 Figure 5 7 Adjustable Skid Shoe MD B6848 The adjustable skid shoes kit allows the header to achieve the desired cutting height for optimum cutting performance Skid shoes are recommended for most c...

Page 191: ...808 1028367 Figure 5 8 Tall Crop Divider MD B6808 Tall crop dividers attach to the ends of the disc header for clean crop division and cutterbar entry in tall crops The kit includes left and right div...

Page 192: ......

Page 193: ...uce header disc speed Foreign object on cutterbar Disengage header and stop engine When all moving parts are completely stopped remove foreign object 4 6 Cutterbar System page 83 Disc not turning Repl...

Page 194: ...Adjust conditioner drive belt tension Conditioner Drive Belt page 160 Symptom Uneven windrow formation in light crop Uneven feeding Reduce header speed Refer to windrower operator s manual Symptom Pl...

Page 195: ...crop sufficiently Decrease roll gap Adjusting Roll Gap Steel Rolls page 54 Symptom Excessive drying or bleaching of crop Excessive crimping Increase roll gap Adjusting Roll Gap Steel Rolls page 54 Cr...

Page 196: ...rbar either too little or too much Drain lubricant and refill with specified amount Draining the Cutterbar page 86 Symptom Spindle bearing failure Material wrapped around spindle Remove disc and remov...

Page 197: ...ve foreign object 4 10 1 Inspecting Conditioner page 158 Belt pulleys and idlers misaligned Align pulleys and idler See MacDon Dealer Symptom Conditioner roll does not rotate Faulty drive belt Check d...

Page 198: ......

Page 199: ...head markings Jam nuts When applying torque to finished jam nuts multiply the torque applied to regular nuts by f 0 65 Self tapping screws Standard torque is to be used NOT to be used on critical or s...

Page 200: ...65 72 48 53 14 2 0 104 115 77 85 16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 1001370 1001370 A Figure 7 3 Bolt Grades Table 7 3 Metric Class 10 9 Bolts and Class 10 Free Spin...

Page 201: ...5 105 8 1 25 26 29 19 21 10 1 5 51 57 38 42 12 1 75 90 99 66 73 14 2 0 143 158 106 117 16 2 0 222 246 165 182 20 2 5 434 480 322 356 24 3 0 750 829 556 614 7 1 2 Metric Bolt Specifications Bolting int...

Page 202: ...ar as possible 3 Check that O ring A is NOT on threads and adjust if necessary 4 Apply hydraulic system oil to O ring A 1003432 D A E B C Figure 7 7 Hydraulic Fitting 5 Install fitting B into port unt...

Page 203: ...3 106 115 4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16 12 176 193 130 14...

Page 204: ...Table 7 7 page 192 6 Check final condition of fitting Table 7 7 O Ring Boss ORB Hydraulic Fittings Non Adjustable SAE Dash Size Thread Size in Torque Value7 Nm lbf ft lbf in 2 5 16 24 6 7 53 62 3 3 8...

Page 205: ...Torque fittings according to values in Table 7 8 page 193 NOTE If applicable hold hex on fitting body E to prevent rotation of fitting body and hose when tightening fitting nut D 6 Use three wrenches...

Page 206: ...ed connector typically 45 or 90 is aligned to receive incoming tube or hose assembly Always finish alignment of fitting in tightening direction Never back off loosen pipe threaded connectors to achiev...

Page 207: ...ressure megapascal MPa x 145 038 pounds per square inch psi Pressure bar Non SI bar x 14 5038 pounds per square inch psi Torque Newton meter Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton...

Page 208: ......

Page 209: ...ll conditioners 54 158 steel rolls 54 conversion chart 195 curtains 45 155 closing 46 inspecting 155 installing 157 opening 45 removing 156 cutterbar angles adjusting angle 52 cutterbar discs 88 cutte...

Page 210: ...ng side deflectors 61 positioning rear baffle 62 positioning rear baffle deflector fins 63 removing 40 G gearboxes 149 conditioner roll timing gearbox checking and changing gearbox oil 149 checking ge...

Page 211: ...6847 171 disc feed plate kit MD 6669 173 double windrow attachment DWA 172 electric remote baffle kit MD 6664 174 polyurethane Intermeshing roller MD B6661 176 steel Intermeshing roller MD B6662 177 t...

Page 212: ...lling 143 removing 139 spindles changing 93 installing 96 removing 94 rotating 93 start up procedures daily start up check 71 T TFFT definition 16 topography 67 torque definition 16 torque angles defi...

Page 213: ...se SAE Multipurpose High temperature extreme pressure EP performance with 1 max Molybdenum Disulphide NLGI Grade 2 lithium base As required unless otherwise specified SAE Multipurpose High temperature...

Page 214: ...16 891 7313 f 816 891 7323 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 f 7 495 967 7600 MacDon Australia Pty Ltd...

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MacDon R216, Operator'S Manual

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